Absorbent article with multi-layer folded absorbent core

Abstract

Absorbent laminates and multi-layer, folded absorbent cores comprising the absorbent laminates for use in absorbent articles are presented. Specifically, multi-layer, folded absorbent cores are presented that are formed from an absorbent laminate comprising an absorbent layer between two tissue layers, in which the absorbent core includes a central channel running longitudinally along the core and crenellations profiled along the thickness of the core and providing enhanced liquid distribution across the core surface area or profile and improved liquid absorption into the laminate.

The invention claimed is: 
     
       1. An absorbent core comprising a longitudinally folded absorbent laminate, the longitudinally folded absorbent laminate comprising:
 an upper laminate layer; 
 a lower laminate layer; and 
 an absorbent layer positioned between the upper laminate layer and the lower laminate layer, the absorbent layer comprising greater than about 90 percent by weight super absorbent polymer (SAP); 
 wherein the longitudinally folded absorbent laminate is folded to form a longitudinally folded multi-layer absorbent laminate of at least five layers of laminate; 
 wherein the longitudinally folded multi-layer absorbent laminate has two lateral laminate sides and a width extending between the laminate sides, a first one of the layers spans the entirety of the width, a second one of the layers is disposed above the first layer and spans between 80 percent and 92 percent of the width, third and fourth layers are disposed between the first and second layers and each span less of the width than does the second layer, and a fifth layer is disposed between the third and fourth layers and spans less of the width than does at least one of the third and fourth layers; and 
 wherein laterally opposing portions of at least the second and third layers define a longitudinally-extending channel above at least the first layer. 
 
     
     
       2. The absorbent core of  claim 1 , further comprising a third laminate layer between the upper laminate layer and the lower laminate layer. 
     
     
       3. The absorbent core of  claim 1 , wherein the channel width is at least about 8 mm wide. 
     
     
       4. The absorbent core of  claim 1 , further comprising a channel insert disposed in the channel, the channel insert configured to improve liquid acquisition and reduce leakage of liquid from longitudinal ends of the channel. 
     
     
       5. The absorbent core of  claim 1 , where at least one of the upper laminate layer and the lower laminate layer comprises tissue. 
     
     
       6. The absorbent core of  claim 1 , wherein the longitudinally folded absorbent laminate further comprises an adhesive between the upper and lower laminate layers. 
     
     
       7. The absorbent core of  claim 6 , wherein the adhesive basis weight is less than about 10% of the SAP basis weight. 
     
     
       8. The absorbent core of  claim 1 , wherein less than 10% of the weight of the SAP particles reside in particles that are greater than 500 μm. 
     
     
       9. The absorbent core of  claim 1 , wherein each layer of laminate comprises a single layer of SAP. 
     
     
       10. The absorbent core of  claim 1 , wherein the SAP content of each layer of the longitudinally folded multi-layer absorbent laminate is from about 40 gsm to about 150 gsm and wherein total SAP content of the layers of the longitudinally folded multi-layer absorbent laminate is from about 7.4 g. to about 18 g and the total SAP content of the layers of the longitudinally folded multi-layer absorbent laminate is between about 240 gsm to about 600 gsm. 
     
     
       11. A disposable absorbent article comprising:
 a body-facing topsheet; 
 a backsheet; and 
 an absorbent core of  claim 1  disposed between the body-facing topsheet and the backsheet with the channel facing the body-facing topsheet. 
 
     
     
       12. The disposable absorbent article of  claim 11 , further comprising a through-air bonded (TAB) acquisition distribution layer (ADL) positioned between the topsheet and the absorbent core, wherein the ADL width is at least 80% of folded core width. 
     
     
       13. The disposable absorbent article of  claim 11 , further comprising a cellulosic acquisition fiber between the topsheet and at least a portion of the absorbent core of  claim 1 . 
     
     
       14. The disposable absorbent article of  claim 11 , wherein the core and the absorbent article are stable and the absorbent article has a stability rating of at least 35 drops. 
     
     
       15. The disposable absorbent article of  claim 11 , further comprising a surge core disposed between the body-facing topsheet and the absorbent core of  claim 1 . 
     
     
       16. The disposable absorbent article of  claim 15 , wherein the surge core comprises a longitudinally folded, multi-layer absorbent laminate defining a longitudinal channel, and the surge core is centered over the channel of the absorbent core of  claim 1 .